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FY i-j' niM *%_> - l - V--'| PLAINTIFFS EXHIBIT \JlRO-120 FINAL REPORT PROJECT NO. ?3li3 SOAKING PIT FACILITIES ARMCO STEEL CORPORATION MIDDLETOWN WORKS KAISER ENGINEERS, INC. i Middletown, Ohio April 30, 1969 AKE-004227 1.0 Introduction On May 21, 196U, a general agreement was entered into between Armco and Kaiser Engineers for engineering, construction and other services related to the Armco expansion program known as Project 600. The Soaking Pits facility is a part of this expansion program. After study and review of many schemes and variations of plans, a Letter of Intent was issued (on March 9, 1966) to the vendor selected to furnish and install the Soaking Pits. This was undertaken prior to the formal approval of the Engineering Report in order to effect a substantial savings in cost of refractories. Formal approval of the 3-Volume Engineering Report No. 71U3-1 (issued May 2, 1966) took place July 1, 1966. The Soaking Pits facility is designed to heat steel ingots to the proper rolling temperature. The ingots vary in size from 23" x 30" x 82" to 78" x hO" x 96" with a maximum weight of 70,000 pounds. The facility as designed meets Phase I requirements, that is to heat 23^,000 ingot tons per month. It consists of twenty-four Soaking Pits arranged in six batteries of four pits each. Each pit is 12'-6" wide, 26'-0" long and 17'-0" deep, and is rated at 200 tons. The pits are serviced by two soaking pit cranes and are installed in a structure 112' wide x 760' long. Included is a liO1 wide covered service area for handling coke breeze and cinders. 1- - AKE-004229 'KS1-. fc;. If:? il;. * Iy\ |;i. Ip I I-!: . r!l :-: is. BIG RED The pits are scheduled for twenty-one (21) turn heating operation, and this factor coupled with the use of the new ingot family will insure the Phase I production requirements. Additional area has been reserved to the east of the Soaking Pit structure so orderly expansion can proceed as required to satisfy future production demands. 2- - AKE-004230 rtfc'sf si fr* ;*!ffi*i*: vr 1,1 h `! ifi1' *;' iff*!'5 ;lif 1 ;! fc-: |S IM :2` Ir:. -. p'lv w.: Ilf j. ipf>-. , US' I" E- ' If If 1.' $ f: -if.lv . f;.:: i-L i;. ; &" l ' spwJ<?., S,'t*i ` fe:' r~:: t-; V|V )S.' :., $J; w^ vf : } jp fev BIG RED 2.0 Organization and Key Personnel . - 2.1 In overall charge of the work for Kaiser Engineers: L. H. Oppenheim - Vice President & General Manager J. E. Hughes - Vice President & Assistant General Manager R. J. Wolf - Vice President Projects W. F. Bort - Vice President, Industrial Construction D. A. Daly - Project Manager C. R. Schwalen - Principal Project Engineer T. L. Nelson - Project Engineer For Armco: W. B. Browning - Director of Engineering to June 1, 196? C. G. Kramer - Director of Engineering after June 1, 1967 F. W. Barnes - Project Manager F. U. Fanning - Project Engineer As shown on the following organization chart, a complete project organization was established in Middletown, staffed with departments for Engineering, Construction, Procurement, Industrial Relations, and Accounting. Cost Control and Planning and Scheduling were staff functions operating directly under the project manager's direction. < -3- AKE-004231 SOAKING PIT FACILITIES ORGANIZATION I AKE-004232 BIG RED 3.0 General Description 3-1 Facility The Soaking Pits faciltiy is located in the South Area as shown on Drawing 625126, South Area, Middletown Works. Ingots are supplied to this facility by Open I-Iearth Shops Mo. 1 and Ho. 2. A major source of ingots in the future will be the new Basic Oxygen Shop due to begin production in-May, 196?. The ingots are received on railroad buggies after being stripped from their molds at the ingot stripper and are i either charged into the pits directly by the pit cranes or stored in the building for future charging. After proper heating or soaking the ingots are withdrawn from the pits by crane, deposited on an ingot buggy and transferred to the Slab Mill for rolling into slabs. The Soaking Pits facility contains approximately 115,000 square feet of floor area under roof which includes the ingot buggy drive houses and the coke breeze and cinder handling area. The Soaking Pits structure is composed of a single main aisle, 760 feet long, 112 feet wide. A lean-to structure, 30 feet wide, frames into the north side of the main aisle over its entire length. The twenty-four pits grouped in six batteries of four pits each are located on the north side of the structure. -5- AKE-004233 } The portion of the enclosure beneath the Soaking Pits has extensive subsurface structures including the basement area, furnace and stack foundations, the cinder tunnel and coke breez.e hopper foundations. Other major substructures include the ingot buggy bumper foundations and the drive house bases. Gravity Ridge ventilators exhaust the heat generated by the Soaking Pits and make-up fresh air is provided by the open wall area on the south side of the structure and louvered intakes on the north side. Two ingot charging tracks run through the building in an east-west direction. These tracks are composed of heavy crane rail sections, structural steel cross ties, a concrete base and are completely encased in concrete for protection against falling ingots. The switch points on the track are provided with gravity type clean outs. The Soaking Pits are serviced by two 35/35 ton pit cranes. These cranes are equipped with cover controls to give the crane operator complete access to the pits. The 35 ton auxiliary hook provides maintenance and cover transportation capability. Two (2) twenty ton maintenance cranes (one on each end of the building) are located in a raised area in the trusses to serve the pit cranes. The 2k Soaking Pits are one way, top fired units capable of operating on natural gas, coke oven gas, or fuel oil and are equipped with recuperators for preheating the burner air. -6- Each pit is 12'-6" wide, by 26'-0" long, by 17'-0" deep to the brick hearth and is rated at 200 tons. The exhaust gas on the four pits in each battery are ducted into a single stack which discharges these gases to the atmosphere 130 feet above ground. The Soaking Pit covers can also be operated from a console located above the pits on the mezzanine floor, as well as from the pit cranes. The combustion control house for controlling the firing of the Soaking Pits is located on the mezzanine floor between Batteries No. 3 and No. l. Various temperatures, fuel rates, and burning ratios are monitored here. A cover repair area, 5>0 feet by 100 feet, is located at the west end of the facility. Cover refractories are removed and relined in this area, which is serviced by a h0-ton semi-gantry crane. Waste material is chuted to the basement for common disposal with the cinders. Coke breeze used for lining of pit hearths is delivered in gon dola cars to the coke and cinder handling facility located north of the pits, unfrozen in cold weather by oil, underfired thawing heaters, discharged into a holding bin and fed by conveyor to coke charging buckets inside the building. Pit cranes carry these buckets to the pits and deposit the coke uniformly over the bottom. A cinder hopper is located under a bell opening in the bottom of . each pit. When the useful, life of the coke has ended, the residue <- AKE-004235 `l i ,J7' ' & I?..-..-1if*P*> a-iilf-' BIG RED is scraped through this opening to the hopper below. A battery driven platform truck is utilized to transport the cinders to a skip hoist for discharge into gondolas. In addition to the natural gas, coke oven gas, and fuel oil piping systems in the Soaking Pits, there are oxygen, low pressure natural gas, grease, steam, plant air (also used as instrument air), well water, furnace cooling water, storm and sanitary piping systems. Electrical power for the pits is fed from the Slab Mill motor room, through the south electrical tunnel to the conduit raceway in the lean-to roof, to the various distribution panels and motor control centers. Soaking Pit cranes and ingot buggy drives are also powered from the Slab Mill motor room. Control and positioning of the ingot buggy is, however, achieved through the ingot buggy pulpit. All of the pits are located west of the ingot receiving table in the Slab Mill, and future expansion east of the Slab Mill is both feasible and practical and should follow the same general arrangement as those pits west of the Slab Mill. 3*2 Facility Requirements and Designed Capability The Soaking Pits will be required to meet the following fore casted production requirements: Phase I - 23^,000 tons of ingots per month. 8- - AKE-004236 .J..; " r-'. BIG RED Production capability has been evaluated on the basis'-of the new l*0-inch big-end-down ingot family which has been established to meet future Middletown Works production requirements. The new ingot size and related representative mix is as follows: Ingot Size Ingot Weight Percent of Total Mix 23" x 1*2" x 96" 21,300 it - 0 37^" x 1*0" x 96" 3l*,000 10.7 37' x 1*1*" x 96" 37,600 8.8 1*0" x 1*9" x 96" 1*5,000 11*.8 1*0" x 5" x 96" 1:0" x 63" x 96" 50,800 58,200 23-1 19-8 1*0" x 71" x 96" 65,800 8.3 1*0" x ?8" x 96" 70,000 10.5 Presently, ingots are being furnished to the new facilities both from the new ingot family and the following present 23" ingot family: Ingot Size Inches Ingot Weight Pounds 30 x 23 x 82 13,U00 36 x 23 x 82 15,200 1*2 x 23 x 82 18,000 50 x 23 x 82 21,200 57 x 23 x 82 21*, 1*00 63 x 23 x 75 25,300 All equipment will accommodate both ingot families although it is planned in Phase I to eliminate the present 23" ingot family from the production requirements as soon as practical. AKE-004237 The following requirements have been established in order to achieve the Phase 1 heating requirements of 235>000 ingot tons per month. o Ingotscharged after h hours track time - lU5,700 tons/mo. o Ingotscharged after 7 hours track time - 72,850 tons/mo. o Ingotscharged cold ----------- l6,U50 tons/mo. o Excessholding time for ingots at rollingtemperature in the pits is one (1) hour maximum for seven (7) hours and two (2) hours maximum for cold charged Ingots, o No excess holding time allotted to li-hour ingots, o Ninety (90) percent of pits available for heating at all times. No more than ten (10) percent down for repairs, o Drawing, standing empty, charging, routine maintenance :?/ . ?;- and rolling mill down time must not exceed 31% of the m i:.: \ pit availability time. The present ingot sizes vary somewhat from those proposed when the Soaking Pit heating studies were made. These modifications are minor, however, and the above criteria for meeting heating requirements are still entirely adequate. BIG RED -10- AKE-004238 U.0 Engineering ii.l Project Engineering Project management, project engineers, technical staff, estimating, planning and scheduling people were all located in a central office in Middletown. This arrangement permitted the close coordination with Armco's engineers and operators and with Kaiser construction personnel. At an initial engineering meeting held on November 25, 1961;, the basic concepts for the soaking pits were discussed and tentatively established. In the next few months many layouts and processes were developed by the project and technical l staff and reviewed along with participating Armc'o engi neering and operating groups. An initial Engineering Report which was combined with the Slab Mill and Stripper was completed in October, 1965* Pro jected cost estimates indicated these facilities to be more expensive than first envisioned. It was, therefore, decided to reduce the overall scope of the project and to publish a separate Engineering Report for the Soaking Pits. This report was issued May'll, 1966. As detail design progressed, project technical staff efforts were utilized to implement the pro ject engineer's efforts relating to detail design direction, dissemination of criteria or information, study efforts, drawing review, and design conformity to scope or accepted scope deviations. -11- BIG RED i AKE-004239 The technical staff maintained a close liaison with the field during the construction period and provided most of the normal field engineering services such as field revisions, as-builts, and implemented changes in scope. The following drawings and specifications were prepared by the Middletown Technical staff for the Soaking Pits project: Drawings Scoping ............................................... lit Civil.................................................... 2 Structural ....................................... 8 Piping ................................................. 8 Mechanical ........................................ 31 Sketches and Layouts................... 162 Specifications Construction/Material Subcontract .................... .. Equipment ...................... ................... l 10 In addition a Sequence of Operations was written by the project engineering group in which operations for both the Slab Mill and Soaking Pits were described. This document clearly defined the operation of the pits, the types of combustion fuels available and pit control systems for each, the computerized ingot identi fication system, as well as detailing the operating and support systems for the entire facility. This manual was issued to the start-up personnel and the operating people as a guide for operations management. -12- AKE-004240 ..y:~.. ^ . . ^ v . . - . - - . ^ v*::-rr.;-.-~.- . ;v:-'-=^T^;.r-.-.'.C:..:-;-'v;V --:-i-i ';.- '^'C ':''-" ' ?.' .- 'v-?"f <i.- v^v^KSS?4^ SV7.'-v . /v`. BIG RED During the last months of construction, preceding the Soaking Pit light-off. Project Engineers moved their offices to the job site to work directly with the field supervision toward completion of the facility and to assist in, and coordinate, the start-up and testing efforts of the Armco, Loftus, Foothill and Kaiser groups. it.2 Detail Design The detail design drawings for the Soaking Pit facilities were prepared in the KE Chicago Office, with the exception of the Soaking Pit furnaces and related appurtenances which were prepared by the Loftus Engineering Company. Soaking Pit - Structure Design of the Soaking Pit Facility was begun in the KE Chicago Office late in December, 1965, and was essentially completed by July 1, 196?. The following summarizes this overall design effort: DRAWINGS Budget Actual MANHOURS Budget Actual Hrs./ Dwg. Struct. 110 111* lh,60ii 13,861 121 Arch. Civil 2U 28 3,30h 2,870 103 33 1?8 177 59 Piping 23 31 Elec. 35 6h Supv. Subtotal ------ 215 --- 2L0 StenoClerical, Gen. Ser., Admin. Total U,221 7,168 2,70li 32i179 3,751 7,650 l,9hh 30,53 121 119 126 3,555 35,73k 3,099 33,352 AKE-004241 i.' BIG RED Soaking Pit - Furnaces Design of the Soaking Pit Furnaces by Loftus Engineering Corporation was begun in May, 1966, and was essentially completed by October 1, 196?, with field changes, etc., being finished at the close of 1968. The following summar ises this drawing effort: Drawings Completed Budget Actual Structural Mechanical Piping Instrumentation 33 21 17 7 hS 33 18 12 Electrical 100 168 Shop Details Totals 73 86 233 362 U*3 Design Features & Methods Several new approaches were taken in the preparation of the detail design for the Soaking Pit facilities. o The trusses and combined building and crane columns were designed as rigid frames. The crane maintenance walkway was located at the top of the crane girder and designed as a horizontal girder to act as horizontal structural bracing members. The wide spacing (five feet) between the building and crane column reduced the column weights and provided adequate crane clearance on the crane walkway. The crane girders were designed to permit free end rotation and yet transmit longitudinal and lateral crane forces into the building columns. -1U- AKE-004242 I- s Iv m: <ri&vSii : %` f. Iv: -;J : - j,i:l:' m BIG RED o Continuously welded crane rails were anchored near the center of the runway, while free-floating crane rail clamps fastened with stud weld holts allow thermal expansion in each direction from the anchors, solving the problem of rail buckling due to high differential heat over the furnaces. o Since the configuration of the Soaking Pit furnaces made it impossible to install X bracing along certain column lines, the building and crane columns at the furnaces were designed to resist bending in both direc tions. This resulted in unique star shaped columns for the Soaking Pits. o A continuous bathtub type foundation was utilized to support the furnace piers, the combined building and crane column piers in the furnace area, the ingot buggy runway, cinder truck passageway and the flue stacks. This arrangement reduced the differential settlement between adjacent pits, building columns, and reduced the dewatering costs. o Primary ingot data and pit information is recorded on a computer for later usage at the computer controlled Slab Mill and Hot Strip Mill, slab scheduling department. o Provision has been made for future expansion of the Soaking Pits in an eastward extension of the present facilities and with a minimum disruption of existing pit operations. -15- AKE-004243 sf. w V-;; ;; n i -i: f t; vj.; y BIG RED ii.U Engineering Costs The Engineering Budget for the Soaking Pit Facilities was $768,000 with a contingency allowance of $77,000 for a total of $8^,000. Engineering Costs-at-Completion compared to the budget are tabulated below; Design Engineering Budget At Completion (Over) Under Middletown $168,000 $150,100 $17,900 Chicago 278,500 209,200 69,300 Subtotal Feasibility $hl46,500 $359,300 $87,200 Engineering 20,000 71,200 (51,200) Reproduction Permits 15,000 5,000 6,500 1,200 8,500 3,800 Outside Services &. Consultants 3,000 1,000 2,000 Chicago Office O.H. 278,500 179,200 99,300 Contingency 77,000 77,000 Total Engineering $8U5,000 $6l8,ltOO $226,600 Percent of Budget (Not Incl. Contingency) 100 81 19 Percent Engineering Complete 100 It.5 Explanation of Engineering Costs The feasibility engineering overrun of $51,200 resulted essentially from the following; -16- AKE-004244 0 Project duration 6 months beyond original schedule, o Extensive scoping studies* necessitated by the change in capacity and layout of the Soaking Pits, dictated by a reduction in capital costs. The Chicago Office direct labor underrun of $69,300 amounted to 2h.9^. This was a result of close coordination between the Middletown project group and the Chicago Design Coordinator, as well as the use of standards and details already developed for the Hot Strip Mill. Loftus Engineering costs were included directly in their coni tract for Design and Installation of the Soaking Pit Furnaces. General Overall engineering costs, excluding the Loftus portion, underran $226,600. Total engineering cost for the Soaking Pits (again excluding the Loftus portion) amounted to 3,&% of the directconstruction cost. -17- AKE-004245 5-0 Procurement 5.1 General Procurement activity for the Soaking Pits commenced with preparation of the standard proposal for the Soaking Pit furnaces which resulted in a subcontract award to Loftus Engineering Company on December 20, 196$, for furnishing i'" and installing 2k pits together with all associated equip ment. There was a total of $6 purchase orders issued for engineered equipment, 2 subcontracts and 218 field pur chase orders covering temporary construction materials, miscellaneous steel, piping valves, and fittings and electric cable and related electrical hardware. 5.2 Engineered Equipment Specifications and inquiries for Engineered Equipment were prepared by the project group, approved by Armco, and then acted upon by the Procurement Department. Bids were evaluated technically by the project engineer and commercially evaluated by the Purchasing Department. A Hr:.i> ; .-U recommendation for placement was prepared and reviewed by the project engineer, the engineering manager, the project manager, and reviewed and approved by Armco. The following purchase orders cover the major items of Engineered Equipment: BIG RED -18- AKE-004246 It ; l"-s fcir'V ' t v. , Vt>'. * .V* *'$o.1J; \i f .ifov- Jl-ivs. ' p- ir Pii'O ! i . ['!*!: ; fW 3-> \\\ v\: yfei- i/.iJq-'*; ' '" r' kr iC ; |K' p |Hi'; er fr r v: H-w h n>- ySa&/{!.ts-!!.;'':/.4!; 1 te'" BIG RED - Armco Purchases 71U397 RP Alliance Machine 2 Soaking Pit EOT Cranes $ 801* ,597 71U3161 RP Cleveland Crane 1*0 T Soaking Pit Gantry Crane 11*6,250 71U3232 RP Alliance Machine 3 - 20 T Repair Cranes 11*5,575 7H*3325 P 711*310893 RP 71U310895 RP 711*310896 General Electric Exide Industrial Portman Equipment Motor Control Center 6 Storage Batteries Fork Lift Truck Moon Equipment 2 Electric Platform Trucks 7,680 10,636 20,11? 29,925 711*310897 Portman Equipment- Fork Lift Truck 10,070 KE Ma.lor Engineered Equipment and Material Purchases 711*31280 Fabreeka Products Fabreeka Pads/ Washers 711*31279 Burt Mfg. Co- Cont. Ridge Type Gravity Vent. 711*31301* Cleveland Crane Crane Collector/ Rail Comp- 711*31372 Stephens-Adamson Cinder Skip Hoist 71U31369 Stephens-Adamson Coke Breeze Handling System 711*311*25 Southern Ohio Fab. Buckets 711*311*67 Ric-Wilj Inc- Prefabricated Conduit 12,51*1* 50,$28 12,710 50,073 37,161* 11*, 700 20,151* 19- AKE-004247 KB Major Engineered Equipment and Material Purchases (Cont.) 711*31509 Dresser Mfg. Couplings 12,302 711*31527 711*3l25 Bethlehem Steel Rex Chainbelt Area Turnouts Ingot Buggy Bumpers 37,300 1*3,000 71It31538 International Steel Structural & Misc, Steel 25,238 711*31583 The Airolite Co. Sidewall Louver 32,200 711*31655 Dave Steel Tong Repair Towers 18,900 53 Field Purchase-Orders Field requisitions were prepared by KE and Foothill from items assigned for Field Procurement on the minor engineered equip ment lists prepared by the KE Design Departments and by direct material take-offs from the construction drawings. Armco manufactured material was requisitioned on field inquiries and sent directly to Armco for their in-plant procurement. 5.1* Subcontracts There were two subcontracts written directly for the Soaking Pits as follows: 711*3-1201* Loftus Eng./Kidde Soaking Pit Fac. $6,599,162 711*3-1671* Delta Pipeline Install Piping 229,970 BIG RED -20- AKE-004248 i'-VK- r r '! pM jin l;> !r * : ** !* . I'i: t I: SI-*- BIG RED In addition, other major subcontracts which pertain in part to work performed in the Soaking Pits, along with the Soaking Pit portion of the cost, are as follows: 7100-1031* International Steel Structural Steel $1,597,535 7100-12#* Ohio Valley Riggers Rebar 219,721 7100-1276 Moraine Ready Mix Concrete 359,921 7100-1087 Stuart Painting Company Structural Steel Painting 1*9,133 7100-1628 Schriber Sheetmetal Built-up Roofing 16,570 711*8-1359 Moeschl-Edwards Rolling Steel Doors 6,71*6 711*8-11*85 Owen-Corning Pipe Insulation 13,833 All subcontracts were administrated by the Subcontract Department located at the jobsite. Weekly status reports were issued for each subcontract, and monthly progress payment requests prepared for approval by Kaiser and Armco Management. -21- AKE-004249 E m t:. ir. & I ; t; : fKt; kAS'' ;V-a t: V u: ^r i )[! r :V BIG RED 6.0 Construction 6.1 General Construction of the Soaking Pits was accomplished by a Kaiser Engineers field organization using Kaiser forces for excavation* concrete* piping* architectural and similar items* Foothill Electric Corporation for the electrical work* and various other subcontractors for millwright work* structural steel* and miscellaneous specialty items. McGraw Construction Company, a subcontractor to Loftus Engineering Company* installed the Soaking Pit furnaces and associated equipment. The Kaiser field organization consisted of the Construction Manager and four principal departments* Construction, Engi neering, Subcontracting, and Warehousing. The construction responsibility for the Soaking Pits was assigned to an area superintendent reporting directly to the general superintendent. Support was provided by the area engineer and the various craft superintendents. 6.2 Progress Construction of the Soaking Pits began in June, 1966, with excavation and dewatering requirements, followed by concrete foundations in September and initial building steel erection on December 13* 1966. During the first year, construction progress consisted mainly of excavation and foundation work. At the close of this year, the job was 13$ complete with lit*000 cubic yards of concrete placed and $00 tons of structural steel erected. -22- AKE-004250 ,ir i "W. -x t\:u mi '4(- - 1 P. $; ' i-i 1^. Wf` 1e*'V-' pi; : |r; ft*.' j>I ..ri; > r; ji it? \& " Ir' BIG RED In 1967, Soaking Pit construction progressed to 72$ complete. Ip April, foundations and building erection advanced to where pit construction together with roofing and siding was started. The first overhead pit crane. No. 357* "was erected in May, followed by crane No. 358 on the first of July. Structural steel erection was completed in August, and roofing and siding in September. Service piping began in November and continued through June, 1968. By the end of this year, Loftus Engineering completed erection of the steel liners for the Soaking Pits together with 80$ of the pit and flue refractory work. Concrete foundations were completed, and i overhead pit crane No. 357 was placed in operation in December, 196?. During the first six months of 1968, remaining construction, including equipment start-up, was essentially completed. An important milestone was reached on July 2, 1968, when batteries h, 5 and 6 were lit-off for dry-out. The Soaking Pit facility provided the ingot re-heat requirements in support of the first ingot processed through the Slab Mill on July 26, 1968. The construction time required to build this facility was twentyfive (25) months. Clean up, punch list and additional work items extended final completion to the end of January, 1969. 6.3 Special Conditions The usage of the overhead pit cranes for construction purposes was limited because after delivery to the jobsite it became necessary to rework the electrical systems for these cranes -23- AKE-004251 to meet Armco's requirements. The existing conduit and wiring was removed and relocated for safety protection. The operator's cab was also modified by lowering it 20 inches and installing a larger front window to improve visibility which had been impaired by the tong columns in their retracted position. a Ah additional 12-week period was required to complete these mod ifications for each crane. However, little lost time can be directly attributed to this problem since mobile truck cranes were used in lieu of overhead cranes. A shortage of skilled craftsmen, mainly pipefitters and electricians, was experienced throughout 196?. Several hundred craftsmen were recruited in other states and Canada to support general manpower requirements. Manpower in the Hot Strip Mill was given priority over other facilities which resulted in lost progress for the Soaking Pits. The Soaking Pits were ready in time, however, to meet the first rolling schedule of the Slab Mill. Reinforcing steel was detailed and fabricated by the sub contractor on site permitting close coordination with the construction forces and easy checking of the drawings which resulted in a considerable saving in time. 6.U Labor Considering the number of craftsmen on the job, very little lost time can be attributed to labor disputes. A walkout by the ironworkers in May, 1966, affected the structural -2li- AKE-004252 i.r rs BIG RED steel erection and a dispute with the electricians in August, 196?, affected the start-up of the Soaking Pits. Peak manpower occurred in December, 196?, when some 375 men were working. A total of 833,728 man-hours were expended on construction. The breakdown by crafts and subcontractors is as follows: Peak Date Peak Man-hours Manpower Occurred Laborers Carpenters 87,1*25 97,762 60 66 Dec. 1966 Jan. 196? Cement Masons 5,1:82 10 Aug. 1967 Teamsters 16,277 8 Aug. 1967 Operating Engrs. Ironworkers Sheetmetal Workers 31,270 55,718 16,2U3 15 30 29 Oct. 1966 June 1967 Aug. 1967 Millwrights Li , O8I4 8 Mar. 1968 Pipefitters 18,6LL 22 May 1967 Electricians Subcontractors: 95,395 78 May 1968 Delta 31,900 36 Jan- 1968 International-Stupp Loftus 27,000 298,L60 25 185 May 1967 Dec. 1967 Ohio Talley Others 35,000 13,070 22 _ May 1967 ----- -25- AKE-004253 ft; ' BIG RED 6.5 Significant Quantities Excavation .......................................................... 7l*,81*8 CY Backfill .............................................................. 115,692 GY Concrete .............................................................. 29*919 CY Equipment Grout...................... 1,250 CF Structural Grout ........................... .... 1,220 CF Reinforcing Steel.... ....................... >6,555,800 LB Structural Steel ............................................ I*,ll8 TN Miscellaneous Steel .................................... 2,26l TN Roofing .............................................................. 81,65U SF Siding ................................................................... 115,762 SF Built-up Roof.................................................. 2l*,9U0 SF Ridge Ventilators . ..................................... 770 LF Piping ................................................................... 3U,790 LF Embedded Conduit.............................................. 1*9,577 LB Exposed Conduit ..................................................13U,61*6 LB Power Wiring (High Voltage) .................. 52,623 LF Power Wiring (Low Voltage) ...................... 2,295 LF Control Wiring ................................................. 10,030 LF Lighting Conduit.............................................. 72,21*0 LB Lighting Wiring...................................................169,1*10 LF Fixtures .............................................................. 552 EA. Welding Wiring.................................................. 22,000 LF Communication Wiring..................................... 11,900 LF Connected Load ................................................. 1*,900 HP -26- AKE-004254 BIG RED BIG RED AKE-004256 ill`I I* * `5s. I 9 Sr n J. & SgitH I J''?'-.'. " -* ;# , W- iSS; iifev BIG RED NaHW AKE-004257 m-' MV:, #3 Iffai'-j1fi:.' m-v} .) :EIi!i, i<1t: IS St ;* 15?.' V 4. .. fl.lv.' (K-1 ! BIG RED 7.0 Progress and Schedules The initial planning of the Soaking Pits project consisted of establishing the overall time frame for the design and construction effort based upon previously completed projects of like magnitude and scope. These time frames were published through the Master Plan schedule and the Engineering Report for the project and served as a time coordinating factor for the various responsible departments and vendors. A bar chart was prepared for issuance with the Engineering Report for the purpose of coordinating design effort to the construction effort and to furnish the major equipment vendor such agreed upon information. On this project, Loftus/Kidde was responsible for the design, fabrication, erection and testing of the Soaking Pits which represented about one half of the direct cost of the project. This schedule, which represented agreed upon basic parameters by various departments, along with the detailed information in the Engineering Report, which included equipment lists and a detailed estimate, became the basis for development of a CPM logic network and subsequent computer output. The resultant data was compiled into a detailed construction schedule bar chart with supporting effort (design, equipment delivery, etc.) delineated in order to show restraints. Included with the CPM output were manpower loading curves based on data extrapolated from the estimate, experience and current information. These curves dictated the manpower required (in crementally and totally) to accomplish the project completion -30- AKE-004258 ft ,!k ! t ,} uif/. r' 'i'i I *!. ' BIG RED date "based on current known and extrapolated data and also afforded a criteria against which to monitor, periodically, the actual manpower accruals. Also furnished by the CPM output was the data required to develop target percentage complete curves of the total job as well as the construction detail increments. These target curves were utilized to apply the actual percent complete figures which" gave an excellent picutre of project status at periodic points in time. In order to make, a periodic determination of progress on the project, a mechanized physical progress report was developed. This report was based on the Chart of Accounts used in the budget estimate. Utilizing quantities in the estimate and an extraction of "labor dollars" from direct labor, equipment usage and sub contract columns, which served as the weighting vehicle, a base was established against which "to-date" quantities were applied on a periodic basis. The resultant calculations gave a percentage of progress on each of the line items within the estimate as well as summating to a percentage of progress for each of the construction detail divisions (i.e., 000 Earthwork, 100 Substructures, etc.) and finally a percentage of progress for the total project. This report served as an extremely valuable and comprehensive tool in the management of the project due to the above capabilities as well as being capable of handling new EAC quantities within the program format. This feature allowed the report to be a dynamic function of the project as alterations occurred. -31- AKE-004259 CPM Summary Reports were issued monthly throughout the duration of the project arid conveyed to management the status of major items of interest within the project. A comparison between the original master schedule dates, current planning schedule dates p::' and expected dates was delineated with an arithmetical days ahead i.i v or behind between the latter two dates, above, given. Kaiser Engineers and the vendor coordinated completion of the pits installation and their start-up. No start-up schedule was prepared for the Soaking Pits project due to the fact the vendor furnishing the pits was responsible for his own start-up. Kaiser '-i-i . i-H- Engineers afforded support in the construction completion and checkout of the building and supporting facilities. BIG RED -32- AKE-004260 $-' !: i!' t: v' (r' iV'i' <v; {* ., IT"" ih' <: i.fe t; :: ' I . i* ; J: BIG RED AKE-004261 BIG RED AKE-004262 8.0 Project Costs The final appropriation for the Soaking Pits as approved by Armco was $15,996,000, which matches the budget estimate shown in the Engineering Report. Overall costs for the project totalled $16,359,200, which ex ceeded the budget by $363,200. This overrun amounted to 2.3 percent of the appropriation. A final Summary Cost and Comparison to Estimate Report is included on the following pages, and significant overruns are i. -i - reported as follows: i The Soaking Pits Structure, Section 201, exceeded the budget by $1:81,825, or 23.h percent. This was primarily due to a low projection on structural steel requirements. Shop, Service and General Enclosures Lighting, Section 262, exceeded the budget by $U6,830. This is offset, however, by a saving of $65,5?2 in High Bay Lighting, Section 26l, a companion account, for an overall saving of $18,?U2. Soaking Pit Cranes, Section 301, overran the budget by $52,112, or 5 percent, which is attributable to the large amount of field rewiring necessary to put the cranes in service. The Soaking Pit Furnace Purchase and Installation, Section 1:01, overran the budget by $U31,369, or 7 percent. This was for premium time payment and settlement of claims for additional compensation by the lower tier erection subcontractor. 35- BIG RED I AKE-004263 BIG RED AKE-004264 mf' ft nii'" r'V *ir-. V,-"- i. (MU-** Oil'?:. -v- &&8&8 88888 & 8S;88888& 388 8 8 8^8 HHHH H H H H H r* H rH H rl rH rH rH 3 & j^gVOCQCU.-*O c 00 row . R Si 8 i'gs $ R^ p, UUOV sJ^ gSV V > o P**iJ ia oj <v o < cj b- p bun-ccoa < _____ LA H H OJ OJ fOH O rHVD -t IT\ IAVO CO b- OJ *=f rH CM CO CO OJ VD -4 w IT\ b- 3 Ov C?> rn ON vo > pa-4 CA ir> cavo * t-'-vo 25 O *H CA X, X, X, -a" H H H H LA VACO W CA x=f\ ro -Sf V^(C| CVJ r-i v-- #HVO fH N^CO Hn I r-f VO 6 O O C P 3 w < ff baO t) H s T5 **H I A 4> 4> tt " ta> a->, oo 5S % o\ 8 m coco cr> o VO vo ia W <\l Ov jH OJ OspJ PA r>HQQ}Hh COCOirsf-O J NO On UN rH cRo CO 1 H1 vo 1 ITvCO^ COg On < ) N- Cu 3 ih 00 no i -VO OMH b-C tAhOOVi? CO VO -4 rH rHVD o s<s 00 Q C*i CVJ CA^f -=f e\ cvi t- ro <n >> VC0OVlAO CqO OOvCCOO - JR > CKVO CO r-f CO >C0 CVJ CO CO o LA CO to LA O CO rn ^ CA rtrt CO CVJ cRotA CAOO CO vovgv^^ Cvj p\ I VO Cb-4 t-- H CO CVJ On laCO CO vo 0\ Q\ H O VO HCO m5\ vo CScAVO ocA*~<i^aD v K X. *V V O * 3c3 cob-l^O O (A 1 CcoO* vo" ^fCOVO 0\ fA 0J CA^ j* Q t*- CA CJ o> on-^ oj r^ LA CA oT :8R *\ OCO CAO LACO (A LACAfA <A rH M CO CVJ ro P# -H O 1) t, tf) p< *d P* 3 < CQ 58: I oa >! :8 s. iA<ArHIVVOO v' o co lacaoj #h o\ca srVp -St f-t pi tA o cQ rH ia.4 o c\j I oa ii CA O CA ^ ^ x, , (A v s , 1A t- LA CO T ` * rW VO CVJ VO il tA ffi 4-> O U e Sp6! Rojmopooo vo vo vo oj ro O- Cf\Qj 0\C\! cn ro r-i tAco COCO tAS o * vo Q\^t b- CO CO CVJ UNCO o co vo o> OJ --iQOJC--0J-? rH<J> OA CV VO On CO VO O CA rH b- LA N> CA <AVO OJ Q CO O VO CO CO r-i VO LA UN CnCQ HUS tA CVJ OyVD CO rH oSOvCOCO s *. O . *^X>X!XX>*.S**y oa i cO H HV o vo & r-1 r-< 8 4CDHA b- On OJ CA OJ CA^t 4f C\ o\-4 cy vo rH CA CA rH VO <AQ4 CO CACVI-4 CA H4 <A rH rH t-- OJ CA cs?OJ r-i VO* +> CJ 4 O 4-> > OCQ C LA 3 > CA .*** . $& kl u?t- 4> P 1A tl t K PAO 5 '.^ . STi ?S .fl I H C Su S CJ k +J 4^ +> .i slN gftl MW3( ! b! < 2uv8 *oU m ; ss* ;gp.3?s| (J O O C! d 3 kSSwwo r-J 55 S 4 4J ) 4J +J cc WI^ p< 3 o o *H 2 -P 3moK fa^ica oo ** a oo O T\ 4* l8 CO H H H H (\) CA-^ IA r-i OJ C> r-i CAVO \D VO VO VO CO CO OJOJCVJOJCVJOJCVJCJOJOJ CA 3 CA IA RSSDAJS3: -5# -5t OH W O r-i CVJ CA^ tLAAH xt CO tQAUQS OUSVQOv\Q>\ & BIG RED AKE-004265 itLi r` i. r;;. nr. :. $1. s fa-'. . : >!5asi!.-*-' sII P j; !i %/ ffjf" a til Wl; il'K I;-. fcp' jt-i. - Kil;l: Sr tr CU ! C I 2 v & 1 t r* Pii* I cc 03 Oi c Eg &<*j\ cj> 8\'S'S\< rH rH & d r u Cou fll J- C5 <P. \tb' 1 VJ U > 1 i^*fs 3-\o o. use ri O* CNCJ CAVO* cStAl/VtA-sT CW r*< fH OJ iH r*4 v^* r*< o> 0> utd8Q tdft ^ Cl O f-* rOAJ i * i trv 3 Io vo co co ir\ irwo t-- o ^-Cs 0 fO* lA*v QI Ot O*n CO*. o*. O UUNVV^Of ttOf\CHO OOvV^OHOT Hfr- toco CO i/\ I : & VO <OC-vCVI CKCO f^lAQ IA- o>ai o > w K *v *. ITvVO COCO U*N9 ITS r-t 1 cQo*..\vOoKlcHa*, os.1O r- co*> s c3 c< 2Ck +6->fl Pa 'Os S8588S8SSS8 -d- NO to r-t CA Cvi eo t----d fO CM CO CO OO CV VO 00 ^s}- iH i-i g . +d> *E oo <z pV t-< rr. j o\co mo 6 i^o\o o o,<wB v ^ I S t * ITVVO CO t*-- Q\MH o co l/N^f \I\ri 00VO CArl o pN f-- On On Q\Q\ ft $ $ aO < CA < vCoVJ VO vo V On . N vITsi CA-d UN wH O On VO H 88 fe cn t/\ oT CO o CA 88 <K 81 8> rH CVI CcDo << VO ^ ft Ov 8_ m CO vrHo co o VO 5 CA s" a iHVO CO <A O vo l/\ rH ChA- v\; C> CO 0A 8 o IA CD S& CO On CM VO* r-i CIAOVCOO JtAt h o S; r-i IIAA -d ro vov 00 o CM *! a vo ITS v VN CA O . VO CA d I E O 4> n SS g ti?<&p 8 &< 0} Of <n -d- uIA*V\vOo t-CO OVCA-d- A R ---O -O-O H rrHl rH-i t-r- Q C* CM CA^ :CSA8t- Q&< 0> C\ On BIG RED AKE-004266 j|;V/ ' It, J-i 'V* f! ': in'1'.'; A" * . 0O0N CWD % $1 0 1 > ua *- *4<) Oh 0! o<o C P, 3 JP < P 8 o % -PUOr{i pa ;4us) suai g $ si cCl/uO\ f 8 l0/N\, CO s VHD &oWpfX*-tc3p3> <r cq N Hl/N g go *8 Iok vp cr: BIG RED AKE-004267 AKE-004268 FINAL REPORT PROJECT NO. 7-lln BIG RED FIGURE 1 Looking west, showing piers along W Line and furnace base slabs being readied for pouring (October 13 1966). AKE-004269 FINAL REPORT PROJECT NO. ?ll|3 FIGURE 2 View looking down cinder tunnel showing furnace piers with rounded steel hullnoses for traffic protection (March 20, 19&7). BIG RED AKE-004270 FINAL REPORT PROJECT NO. ?ll43 f BIG RED FIGURE 3 Aerial view looking north with soaking pits in foreground with building framing steel approximately 90% complete (April 23, 1967). AKE-004271 FINAL REPORT PROJECT JfO. 7IU3 FIGURE h Looking northeast at the east end of the building showing soaking pit crane 3f>? bridge girders and wheel trucks in place (May 2%, 1?6?). BIG RED AKE-004272 FINAL REPORT PROJE.CT JTO. 71U3 FIGURE 5 . Showing the first siding being erected along the W Line along with structural steel bolt-up activity (May 196?). BIG RED AKE-004273 BIG RED FINAL REPORT PROJECT N.O. 7113 AKE-004274 Looking west showing the t r o lle y components being erected f o r soaking p i t crane 35>8 (J u ly 11, 1967) FINAL REPORT PROJECT.UP. 7I1l3 FIGURE 7 Looking west showing the sidewalls and carriage beams erected on Pits 2h and 23 and floor steel in place on subsequent pits (August 2$, 1967). BIG RED AKE-004275 FIGURE 8 View showing completed steel work on the soaking pit structures and refractory brick on operating floor level (October 30, 196?). BIG RED AKE-004276 FINAL REPORT PROJECT NQ. 71l4i FIGURE 9 Aerial view looking north with soaking pits in foreground and slab itd 11 and strip mill beyond showing general! siding and roofing progress (December 26, 1?67). BIG RED, ORANGE AKE-004277 PINAL REPORT PROJECT'NO. 71h3 FIGURE 30 Looking west showing ingot buggy trackwork and pit wall armor p3ating (February 8, 3.968). BIG RED AKE-004278 FINAL REPORT PROJECT NO. 71h3 FIGURE II View looking northeast showing general completion of refractory lining of pits with cover I.ining activity shown in front of pits (July 2, 2?68). BIG RED AKE-004279 FINAL REPORT PROJECT NO. 7Ih3 FIGURE 12 View looking northeast showing Ingot buggy in position to receive a hot ingot being withdrawn from pit 21 by soaking pit crane 35? (August 1, 1968). BIG RED AKE-004280 10.0 General Arrangement Drawings Drawing Mo. 62^126 637001 637002 637005 637027 637028 Description Site Plan General Plan - West Half General Plan - East Half Cross Section - Typical Soaking Pit Cross Section - Cover Repair Area and Battery Room Cross Section - Service Bay t BIG RED i -53AKE-004281 BIG RED AKE-004282 BIG RED AKE-004283 BIG RED j 637002 AKE-004284 . _IdJiiiJJiUiUiilufiiljliiUU BIG RED AKE-004285 BIG RED AKE-004286 BIG RED AKE-004287 < AKe-004,45